Nonwoven, and process and apparatus for producing the same

ABSTRACT

The present invention relates to a process for making a fibrous web comprising a plurality of first areas comprising hydroentangled fibers, the first areas being discrete in a machine direction and/or a counter-machine direction, the process comprises subjecting a fibrous web to a hydroentanglement process directing water jets from a water injection means on to the fibrous web, and blocking at least one of the water jets from the water injection means discontinuously using a first blocking member positioned between the water injection means and the fibrous web wherein the first blocking member comprises at least one aperture, or at least one recess on its surface, and is rotatable about an axis perpendicular to a z-direction.

FIELD OF THE INVENTION

The present invention relates to a process for producing spunlacenonwoven having patterns and an apparatus suitable for the process.

BACKGROUND OF THE INVENTION

Nonwovens are widely used in a variety of personal care productsincluding, for example feminine hygiene products such as sanitarynapkins, liners and tampons, diapers and wipes since it is soft and hasfabric like appearance.

Various nonwovens have been suggested for use as a component such astopsheets for absorbent articles from the standpoints of skin sensation,a feeling of dryness, comfort, absorption of expelled bodily fluids, andprevention of fluid flow-back.

It was recognized that it is also desirable in certain applications fornonwoven to be bulky. It is also desirable that nonwovens have a visibleimage or pattern at least one surface thereof as considered thatnonwoven having images or patterns may have a breathable appearance, anddelight users with a unique pattern.

In nonwovens made by conventional spunlacing, images or decorations innonwoven material can be produced by hydroentangling. As is generallyknown in the art, hydroentanglement (sometimes referred to asspunlacing, jet entanglement, water entanglement, hydroentanglement orhydraulic needling), is a mechanical bonding process whereby fibers of afibrous web are entangled by means of high pressure water jets. Inhydroentanglement processes, patterning on a fibrous web can be achievedby use of patterned supports such as drums and belts which cause thefibers to form a negative image of the design on the support in thefibrous web. Conventional hydroentanglement process may not achieveclearly visible patterns in nonwoven as a sufficient difference inthickness or density between the images or decorations in a nonwovenover a background area in the nonwoven is not provided as water flow isapplied to the entire surface of the nonwoven. In addition, it is costlyto switch to different patterns as a support having a different imagetransfer surface is expensive.

WO2012/73544A discloses a nonwoven web comprising first entanglementparts and second entanglement parts which form wavy lines along amachine direction of the nonwoven web. According to WO2012/73544A, afiber web is first hydroentangled to form an entangled web and the firstparts, and the entangle web is second hydroentangled to form the secondentanglement parts. In the second hydroentangling, water jets ejectedfrom a water injector pass through perforations of a perforated memberand strikes the entangled web to form the second entanglement parts.Portions of the entangled web where the water jets during the secondhydroentanglement do not reach remain the first hydroentanglement parts.

It is desirable to provide a process for producing nonwoven and formingvarious patterns by hydroentanglement in a cost effective way.

It is also desirable to provide a process for producing nonwoven andforming various patterns by hydroentanglement without compromisingbulkiness of nonwoven.

SUMMARY OF THE INVENTION

The present invention relates to a process for making a fibrous webcomprising a plurality of first areas comprising hydroentangled fibers,the first areas being discrete in a machine direction. The processcomprises subjecting a fibrous web to a hydroentanglement processdirecting water jets from a water injection means on to the fibrous web,and blocking at least one water jet from the water injection meansdiscontinuously using a first blocking member positioned between thewater injection means and the fibrous web, wherein the first blockingmember comprises at least one aperture or recess, and rotates about anaxis perpendicular to a z-direction.

The present invention also relates to an apparatus for forming atextured spunlace nonwoven web comprising a support, a water injectionmeans in associated with the support, a first blocking member disposedbetween the support and the water injection means, wherein the firstblocking member comprises at least one aperture or recess, and isrotatable about an axis perpendicular to a z-direction.

The present invention also relates to a nonwoven web having a length anda width, and comprising a plurality of first areas, and at least onesecond area located between two adjacent first areas in a nonwovenlengthwise direction, wherein the plurality of first areas comprisehydroentangled fibers, wherein each of the plurality of first areascomprises at least two apertures or depressions, and a land between thetwo apertures or depressions, and wherein the land in the first area hasa higher fiber density or a higher degree of fiber entanglement than thesecond area.

The present invention also relates to a laminate comprising a firstlayer comprising a nonwoven web of the present invention.

The present invention also relates to an absorbent article comprising alayer comprising a nonwoven web or a laminate of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like numerals or other designations designate likefeatures throughout the views.

FIG. 1 is a schematic representation of a process for making a nonwovenaccording to the present invention.

FIG. 2 is a schematic partial side view of the process in FIG. 1 .

FIG. 3A is a schematic partial perspective view of the process in FIG. 2.

FIG. 3B is another schematic partial perspective view of the process inFIG. 2 .

FIG. 3C is another schematic partial perspective view of the process inFIG. 2 .

FIG. 4A is a z-direction cross-section view of a first blocking memberin FIG. 3A.

FIG. 4B is a z-direction cross-section view of another first blockingmember in the present invention.

FIG. 4C is a z-direction cross-section view of another first blockingmember in the present invention.

FIG. 4D is a side view of another first blocking member in the presentinvention.

FIG. 4E is a z-direction cross-section view of the first blocking memberof FIG. 4D.

FIG. 4F is a side view of another first blocking member in the presentinvention.

FIG. 4G is a z-direction cross-section view of the first blocking memberof FIG. 4F.

FIG. 5 is a schematic representation of another process for making anonwoven according to the present invention.

FIG. 6 is a plan view of a nonwoven according to the present invention.

FIG. 7 is a plan view of another nonwoven according to the presentinvention.

FIG. 8 is a plan view of another nonwoven according to the presentinvention.

FIG. 9 is a perspective view of one example of an absorbent article thatincorporates a nonwoven according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of an absorbent articlecomprising back ears having unique engineering strain properties and lowsurface roughness. One or more examples of these non-limitingembodiments are illustrated in the accompanying drawings. Those ordinaryskilled in the art will understand that the absorbent articles describedherein and illustrated in the accompanying drawings are non-limitingexample forms and that the scope of the various non-limiting forms ofthe present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting form may becombined with the features of other non-limiting forms. Suchmodifications and variations are intended to be included within thescope of the present disclosure.

“Absorbent article” refers to wearable devices, which absorb and/orcontain liquid, and more specifically, refers to devices, which areplaced against or in proximity to the body of the wearer to absorb andcontain the various exudates discharged from the body. Absorbentarticles can include diapers, training pants, adult incontinenceundergarments, and feminine hygiene products such as sanitary napkinsand pantyliners.

“Machine direction” or “MD” as used herein means the direction parallelto the flow of the hydroentangled fibrous web through the hydroentangledfibrous web making machine and/or absorbent article productmanufacturing equipment.

“Cross machine direction” or “CD” as used herein means the directionparallel to the width of the hydroentangled fibrous web making machineand/or absorbent article product manufacturing equipment andperpendicular to the machine direction.

“Z-direction” is orthogonal to both the longitudinal and transversedirections. It is orthogonal to both the machine and cross-machinedirections when the term is used with respect to a nonwovenmanufacturing process.

“Disposable” is used herein to describe articles that are generally notintended to be laundered or otherwise restored or reused (i.e., they areintended to be discarded after a single use and, may be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

“Absorbent core” refers to a structure typically disposed between atopsheet and backsheet of an absorbent article for absorbing andcontaining liquid received by the absorbent article. The absorbent coremay comprise one or more substrate layer, absorbent material disposed onthe one or more substrate layer, and a thermoplastic adhesivecomposition on the absorbent material. The thermoplastic adhesivecomposition may be on the absorbent material and at least a portion ofthe one or more substrate layer. The absorbent core does not include anacquisition system, a topsheet, or a backsheet of the absorbent article.In a certain embodiment, the absorbent core would consist essentially ofthe one or more substrate layers, the absorbent material, thethermoplastic adhesive composition, and optionally a cover layer.

“Nonwoven” refers to a manufactured web of directionally or randomlyorientated fibers, excluding paper and products which are woven,knitted, tufted, stitch-bonded incorporating binding yarns or filaments,or felted by wet-milling, whether or not additionally needled. Nonwovenmaterials and processes for making them are known in the art. Generally,processes for making nonwoven materials comprise laying fibers onto aforming surface, which can comprise spunlaying, meltblowing, carding,airlaying, wetlaying, coform and combinations thereof. The fibers can beof natural or man-made origin and may be staple fibers or continuousfilaments or be formed in situ.

As used herein, the term “comprising” means that the various components,ingredients, or steps can be conjointly employed in practicing thepresent invention. Accordingly, the term “comprising” is open-ended andencompasses the more restrictive terms “consisting essentially of” and“consisting of”.

Process

FIG. 1 depicts a simplified, schematic view of an exemplary process formaking a nonwoven according to the present invention comprising a firsthydroentanglement process, and FIG. 2 depicts a schematic side view ofthe first hydroentanglement process in the process in FIG. 1 . Referringto FIGS. 1 and 2 , the process according to the present inventioncomprises subjecting a fibrous web 30 to a first hydroentanglementprocess directing water jets 36 from a water injection means 32 on tothe fibrous web 30, and blocking at least one of the water jets 36 fromthe water injection means 32 discontinuously during the firsthydroentanglement process. The blocking at least one of the water jets36 from the water injection means 32 discontinuously is carried out by ause of a first blocking member 50 positioned between the water injectionmeans 32 and the fibrous web 30. The first blocking member 50 rotatesabout an axis perpendicular to a z-direction, so that it blocks at leastone water jet from the water injection means 32 discontinuously alongits rotation.

Fibers forming a fibrous web can be of natural or man-made origin andmay be staple fibers or continuous filaments or be formed in situ. Thefibrous web which can be of various fibrous components (usually airlaid,wetlaid, or carded, but sometimes spunbond or melt-blown, etc.) canfirst be compacted and prewetted to eliminate air pockets prior tosubjecting to a hydroentanglement process.

With reference to FIG. 1 , a fibrous web 30 may have a pre-firsthydroentanglement process portion 30A upstream of a firsthydroentanglement process and a post-first hydroentanglement processportion 30B downstream of the first hydroentanglement process. Thepre-first hydroentanglement process portion 30A may be unbonded, bebonded, or be entangled. During the first hydroentanglement process, thefibrous web 30 is passed by the water injection means 32 that comprisesa plurality of orifices supplying a plurality of water jets. Theplurality of orifices may be positioned to generally form a watercurtain. Water jets 36 are directed through the fibrous web 30 at highpressures. The fibrous web 30 can be supported by any suitable supportmember 40, such as a moving wire screen or on a rotating porous drum,for example. As the water jet 36 penetrates the fibrous web 30, asuction slot 38 positioned proximate beneath the fibrous web 30 collectsthe water which may be filtered and returned to the water injectionmeans 32 for subsequent injection. The water jet 36 delivered by thewater injection means 32 exhausts most of its kinetic energy primarilyin rearranging fibers within the fibrous web 30 to turn and twist thefibers to form a series of interlocking knots.

Still referring to FIGS. 1 and 2 , in the process of the presentinvention, at least one of the water jets 36 from a water injectionmeans 32 is discontinuously blocked by use of a first blocking member 50disposed between the water injection means 32 and the fibrous web 30 (orthe support member 40) by rotating the first blocking member about anaxis perpendicular to a z-direction.

A first blocking member in the present process comprises at least oneaperture, or at least one recess on its surface. The first blockingmember is explained in detail in the Apparatus section below.

In one embodiment, referring to FIGS. 3A and 3B, the first blockingmember 50 comprises at least one aperture 52 and a non-apertured area54. The first blocking member 50 rotates about an axis perpendicular toa z-direction to have a first position, a blocking position, such as inFIG. 3A where the first blocking member 50 blocks at least one water jet36 a from the water injection means 32, and a second position, an openposition, such as in FIG. 3B where the first blocking member 50 does notblock the at least one water jet 36 a so that the at least one water jet36 a passes through the aperture 52 alternately.

In some embodiments, referring to FIGS. 3A-3C, the first blocking member50, while it is rotating along the axis X, moves back and forth along afirst axis between a first position or a blocking position such as inFIG. 3A or 3C where the first blocking member 50 blocks the water jet 36a from the water injection means 32 and a second position or an openposition such as in FIG. 3B where the first blocking member 50 does notblock the water jet 36 a from the water injection means 32. The firstblocking member 50 may maintain a blocking position and an open positionalternately.

Blocking a water jet from a water injection means intends to mean thatthe water jet from the water injection means is blocked and is notdirected to a position in a fibrous web where the water jet is supposedto hit if it is not blocked. Not-blocking a water jet from a waterinjection means intends to mean that the water jet from the waterinjection means is directed to a fibrous web along an axis in az-direction. Referring to FIGS. 3A and 3C, when the first blockingmember 50 is in a blocking position, at least part of the non-aperturesarea 54 of the first blocking member 50 is positioned between the waterinjection means and the fibrous web 30, so that the first blockingmember 50 blocks a water jet 36 a from the water injection means 32.When the first blocking member 50 is in an open position, referring toFIG. 3B, the water jet 36 a from the water injection means 32 isdirected to on the fibrous web 30 through an aperture 52 in the firstblocking member 50. Though FIGS. 3B and 3C indicate one water jet passesthrough an aperture 52 of the first blocking member 50, numbers of waterjets passing through one aperture 52 at a given moment can be adjustedconsidering on a design of aperture shape and size.

The first blocking member 50 may maintain a blocking position and anopen position alternately in a constant speed or in a non-constantspeed. By repeating the blocking position and open position alternately,a plurality of first areas discrete in a machine direction are formed inthe fibrous web.

Areas in fibrous web 30 hit by the water jet 36, 36 a go through fiberentanglement during the first hydroentanglement process and form theplurality of first areas discrete in the machine direction.

In some embodiments, a process according to the present inventioncomprises subjecting a fibrous web to a first hydroentanglement processdirecting water jets from a water injection means on to the fibrous web,blocking at least one water jet from the water injection meansdiscontinuously by use of a first blocking member positioned between thewater injection means and the fibrous web, and blocking the at least onewater jet from the water injection means discontinuously while the atleast one water jet is not blocked by the first blocking member. Theblocking the at least one water jet from the water injection means maybe conducted by use of a second blocking member.

The second blocking member comprises a non-apertured area. The secondblocking member may comprise an aperture. The second blocking member ismovable back and forth along a second axis between a third position, ablocking position, where the second blocking member blocks the at leastone water jet from the water injection means and a fourth position, anopen position, where the second blocking member does not block the atleast one water jet from the water injection means. The second blockingmember may be positioned between the water injection means and the firstblocking member. The second blocking member may be positioned betweenthe first blocking member and the fibrous web (or a support). The secondaxis may be parallel to the first axis along which the first blockingmember moves back and forth. The second axis may not be parallel to thefirst axis. The second blocking member may maintain the third positionand fourth position alternately. The second blocking member may maintainthe third position and fourth position alternately in a constant speedor in a non-constant speed.

With rotating and moving the first blocking member and the optionalsecond blocking member during hydroentanglement process, variouspatterns of the plurality of first areas directed in a machine directioncan be formed. Patterning can be achieved by discontinuoushydroentanglement on a fibrous web by the process of the presentinvention. A fibrous web 30 in FIGS. 3A-3C has a plurality of firstareas discrete in a machine direction in a post-first hydroentanglementprocess portion 30B, though it is not reflected in FIGS. 3A-3C only forthe purpose of simplicity.

The term “rotate” or “rotation” refers to the case where the blockingmember rotates in one direction, or where the blocking member rotatesreciprocated.

The first axis along which the first blocking member moves and thesecond axis along which the second blocking member moves may beappropriately selected as a machine direction, a cross machinedirection, an oblique direction, and the like. Here, the obliquedirection refers to a direction along the plane of the nonwoven fabric,or a direction in a range of more than 0 degrees and less than 90degrees with respect to the machine direction or cross machinedirection. In consideration of the ease of manufacture, the axes of thefirst and/or second blocking members vibration is preferably in thedirection of the machine direction or cross machine direction, or adirection wherein the angle between the direction and the machinedirection or cross machine direction is in the range of 0 degree to 45degrees. In addition, the phrase “move back and forth” or “back andforth” refers to the case where the blocking member is reciprocated in acertain direction, including the case where it is reciprocated in astraight line, and the case where it is reciprocated along a circularorbit having a long axis in a certain direction. In addition, the movingdirection of the first and/or second blocking members may be parallel toor not parallel to the lengthwise direction of the blocking member, andthe angle between the lengthwise direction of the blocking member andthe moving direction may also be changed during a process. In theprocess of the present invention, the blocking positions (the firstand/or third position) and/or the open positions (the second and/orfourth position) may remain in the same positions during the process, ormay change during the process of the present invention as long as ablocking member blocks at least one water jet from a water injectionmeans at a blocking position and the blocking member does not block theat least one water jet from a water injection means at an open position.A moving speed of the first blocking member or the optional secondblocking member may be the same. The first blocking member and thesecond blocking member may move in different speeds.

Hydroentangling conditions may be appropriately set depending on theweight per unit area of the web, and/or the speed of the transportsupport when the support member comprises a belt. For example, a waterinjection means with orifices having a pore size of about 0.05 to about0.5 mm at an interval of about 0.2 to about 1.5 mm may be used, andwater flow having a water pressure of about 1 to about 20 MPa may besprayed about 1 to about 4 times to the front side and the back side ofthe web, respectively. More preferably, the water pressure is about 1 toabout 10 MPa. When the water pressure is less than 1 MPa, the entanglingbetween the fibers may become insufficient, and the resulting nonwovenweb may be liable to fluff shedding. When the water pressure exceeds 20MPa, the entangling among the fibers may become too strong, the degreeof freedom of the fibers may be reduced, the nonwoven web may feelhardened, or the texture of the nonwoven web may be deteriorated.

Once the fibrous web has been hydroentangled, the hydroentangled fibrousweb is dried for example, by being passed through a dewatering devicewhere excess water is removed. The hydroentangled fibrous web afterbeing dried, may be further treated with additional heat especially whenthe fibrous web includes synthetic fibers. The synthetic fibers begin tosoften, and these softened fibers touch each other, bonds will formbetween the fibers, thereby increasing the overall flexural rigidity ofthe structure due to the formation of these bond sites. The elevatedtemperature of the hydroentangled fibrous web is not high enough,however, to cause other types of fibers within the hydroentangledfibrous web to flow or otherwise soften, bond, or collapse. Theformation of the bond sites within the hydroentangled fibrous web addsstiffness to the web, yet the fluid handling performance of thehydroentangled fibrous web remains as desired. It will be recognizedthat raising the final drying stage temperature (or otherwiseintroducing heat to the hydroentangled fibrous web) to just above asoftening temperature of a portion of the bicomponent fiber provides anincrease in mechanical performance while also maintaining liquidhandling performance. If, however, the hydroentangled fibrous web isheated to too high of temperature, the rigidity of the structureincreases and the liquid handling performance of the structure cansuffer.

The process of the present invention may further comprise at least oneadditional entanglement process such as a hydroentanglement prior to orafter the first hydroentanglement process. In one embodiment, referringto FIG. 5 , the process of the present invention may further comprise anadditional hydroentanglement process using a water injection means 321supplying waterjets 361 before the first hydroentanglement process usinga water injection means 322 supplying water jets 362. Water jets 361from water injection means 321 and water jets 362 from water injectionmeans 322 may or may not be at the same pressure. The particular numberof water injection means utilized for the process of the presentinvention can be determined based on, for example, desired basis weight,degree of bonding required, characteristics of the web, and so forth.

In some embodiments, a process according to the present invention mayfurther comprise subjecting the fibrous web to a secondhydroentanglement process. As one example of such embodiments, a processaccording to the present invention comprises subjecting a fibrous web toa first hydroentanglement process directing water jets from a firstwater injection means on to the fibrous web, blocking at least one waterjet from the first water injection means discontinuously during thefirst hydroentanglement process using a first blocking member,subjecting the fibrous web to a second hydroentanglement processdirecting water jets from a second water injection means on to thefibrous web, and blocking at least one water jet from the second waterinjection means discontinuously during the second hydroentanglementprocess.

The blocking at least one water jet from the second water injectionmeans may be conducted by use of a third blocking member. The thirdblocking member in the second hydroentanglement process may be similarto the first or the optional second blocking member described herein interms of blocking member shape and structure. The third blocking memberis positioned between the second water injection means and the fibrousweb, and rotates or moves between a blocking position where the thirdblocking member blocks at least one water jet from the second waterinjection and an open position where the third blocking member does notblock the at least one water jet from the second water injection.

A process according to the present invention can provide nonwoven havinga plurality of first areas comprising hydroentangled fibers discrete ina machine direction and at least one second area located between twoadjacent first areas in the machine direction. Each of the plurality offirst areas may comprise at least two apertures or depressions, and aland between the two apertures or depressions. The land in the firstarea and may have a higher fiber density or a higher degree of fiberentanglement than the second area.

With the second hydroentanglement process, a process according to thepresent invention can provide nonwoven having a plurality of first areasand at least one second area described herein, and a plurality of thirdareas comprising hydroentangled fibers discrete in a machine directionor in a cross-machine direction. Each of the plurality of third areasmay comprise at least two apertures or depressions, and a land betweenthe two apertures or depressions. The land in the first area and theland in the third area may have a higher fiber density or a higherdegree of fiber entanglement than the second area.

Apparatus

An apparatus useful for the process of the present invention, referringto FIGS. 3A-3C, comprises a support member 40; a water injection means32 in associated with the support member 40, and a first blocking member50 disposed between the support member 40 and the water injection means32.

A water injection means in the present invention may comprise aplurality of orifices. The plurality of orifices may be positioned togenerally form a water curtain. The plurality orifices may compriseorifices arranged at a fixed or variable interval. The plurality oforifices may comprise a plurality of orifice groups each of whichcomprises two or more orifices. A width of one orifice group and/or aspace between adjacent orifice groups may be determined depending onpatterns to be formed on the fibrous web 30. When the number of orificesincluded in one orifice group is 2 or more, the interval betweenadjacent orifices in one orifice group may be smaller than the spacebetween the orifice group and an adjacent orifice group.

The first blocking member in the present invention comprises at leastone aperture, or at least one recess on its surface, and is rotatableabout an axis X perpendicular to a z-direction. By rotating, the firstblocking member can be either in a first position or a blocking positionwhere it blocks at least one water jet from the water injection means ora second position or an open position where it passes the at least onewater jet from the water injection means. The first blocking member 50may be any member regardless its geometric shape or material compositionas long as it can block at least one water jet from a water injectionmeans 32 in a first position, and can pass the at least one water jetfrom the water injection of the water injection means at the secondposition during rotation. The first blocking member may also move backand forth along a first axis, while it is rotating.

Referring to FIGS. 3A-3C, the first blocking member 50 may be a rotatorybar such as a cylinder-shape rotatory bar, for example. The firstblocking member 50 comprises at least one aperture 52 and anon-apertured area 54. By rotating, the first blocking member 50 may ina first position or a blocking position where it blocks at least onewater jet from the water injection means 32, and a second position or anopen position where it passes the at least one water jet from the waterinjection means 32 through an aperture 52 alternately.

The first blocking member comprises at least one aperture and/or atleast one recess.

For example, the first blocking member may comprise a plurality ofapertures. In one embodiment, referring to FIG. 3A, the first blockingmember 50 may has a plurality of discrete apertures formed in a length(“L”) direction of the first blocking member 50. FIG. 4A shows across-section view of the first blocking member 50 of FIG. 3A at an areawhere an aperture is formed. In some embodiments, a first blockingmember 50 may have multiple rows of a plurality of discrete aperturesalong a length of the first blocking member 50. For example, FIG. 4Bshows a z-direction cross-section view of a first blocking member 50having two rows of a plurality of discrete apertures 52 along a lengthof the first blocking member 50 at an area where at least one apertureis formed. Apertures in a first row and apertures in a second raw do notcross each other. The two rows of apertures may be parallel to eachother. The two rows of apertures may be arranged in a staggered manner.As another example, FIG. 4C shows a z-direction cross-section view of afirst blocking member 50 having two rows of a plurality of discreteapertures 52 formed along a length of the first blocking member 50. Inthis example, apertures in a first row and apertures in a second rawcross each other. First blocking members 50 in FIGS. 4A-4C have at leastone aperture 52 and a non-apertured area 54. The plurality of apertures52, though FIG. 3A shows a plurality of apertures 52 formed along alength of the first blocking member 50, can be formed in any directionor in random.

A first blocking member in the present invention may comprise at leastone recess on its surface. FIG. 4D is a side view of another firstblocking member 50 in the present invention having four recesses 53extending along a length, L, of the first blocking member 50. FIG. 4E isa cross-section view of the first blocking member of FIG. 4D along a z-zline. A Recess or recesses on the first blocking member does not need toextend along the entire length of the first blocking member 50. FIG. 4Fis a side view of another first blocking member 50 having two rows of aplurality of discrete recesses 53 formed along a length of the firstblocking member 50. FIG. 4G is a cross-section view of the firstblocking member 50 of FIG. 4F along a z-z line. First blocking members50 in FIGS. 4D-4G have at least one recess 53 and at least onenon-recessed area 54.

In another embodiment, the apparatus according to the present inventionmay further comprise a second blocking member positioned either betweenthe water injection means and the first blocking member or between thefirst blocking member and the support member. The second blocking membermay comprise at least one aperture, and is movable back and forth alonga second axis between a third position or a blocking position where thesecond blocking member blocks the at least one water jet from the waterinjection means, and a fourth position or an open position where thesecond blocking member does not block the at least one water jet fromthe water injection means.

An aperture in a blocking member, the first blocking member and/or anyadditional blocking member means an aperture through which at least onewater jet from the water injection means can pass when the blockingmember is in an open position. Therefore, when the blocking member has avoid inner space, one aperture may intend to mean a pair of aperturesthrough which at least one water jet from the water injection means canpass through when the blocking member is in the open position.

The aperture or recess in a first blocking member may be in any shape,for example, preferably, a circular shape, a semicircular shape, anelliptical shape, a polygonal shape such as a triangular shape or aquadrilateral shape, a star polygon, a cross shape, and a slit shapesuch as a straight line shape or a curved line shape. The aperture orrecess in the first blocking member may have a width of about 2 mm ormore, or about 3 to 50 mm, or about 5 to 30 mm. When the first blockingmember has a plurality of apertures, the interval between adjacentapertures in the first blocking member may be about 2 mm or more, orabout 3 to 50 mm, or about 5 to 30 mm. Descriptions of apertures withrespect to the aperture in a first blocking member are applied tooptional aperture(s) in a second blocking member.

The first blocking member and/or the second blocking member can be madeof, for example, synthetic resin, metal, or the like. In addition, theshape may be appropriately selected as a plate, a roll or the likesuitable for a hydroentanglement process of the present invention.

A distance between the water injection means and a blocking memberclosest to the water injection means may be about 1 mm or about 2 mm, ormore, and is adjustable considering equipment design, space between awater injection means and a support. When the distance between theblocking member and the water injection means is less than 1 mm, theblocking member and the water injection means may be in contact witheach other, and one or both of them are damaged. A distance between theblocking member (the blocking member located in the highest positionwhen the apparatus has more than one blocking member) and the orificemay be about 30 mm or less. A distance between the fibrous web and theblocking member closest to the fibrous web may be about 5 mm to 50 mm.When the distance between the blocking member and the fibrous web isless than 5 mm, the fibrous web may be damaged by the contact betweenthe blocking member and the fibrous web. When the distance between theblocking member and the orifice may be more than 30 mm or the distancebetween the blocking member and the fibrous web exceeds 50 mm, theenergy of the water flow may be reduced and the entanglement may becomeinsufficient.

Support may be in the form of a moving wire screen, rotating porousdrum, or the like known in the art suitable for a hydroentanglementprocess. The support may have a patterned surface exhibitingdepressions, apertures, and/or projections. The fibrous web receives itsimage or decoration against the wire gauze, plate or drum by beingformed respectively against depression, apertures and/or projectionswith the help of water jets.

Nonwoven

A nonwoven which can be produced by the process of the present inventiondescribed in detail herein has a length and a width, and comprises aplurality of first areas comprising hydroentangled fibers and at leastone second area located between two adjacent first areas in a nonwovenlengthwise direction, so that the plurality of first areas are discretein the nonwoven lengthwise direction. The nonwoven lengthwise directioncorresponds to a machine direction in a nonwoven making process.

Each of the first areas comprises at least two apertures or depressions,and a land between the two apertures or the two depressions. The land inthe first area has a higher fiber density or a higher degree of fiberentanglement than the second area as the first area went throughadditional hydroentanglement process. The land in the first area mayhave a thickness in a z-direction lower than the second area as thefirst area went through additional hydroentanglement process.

The second area may be in the state of any of fiber assemblies, such asthe state of unbonded web, the state of bonded web, the state ofentangled web, and the like, and are not particularly limited. In someembodiments, the second area comprises entangled fiber. The entanglementof fibers in the second area can be carried out by any method such as aneedle punching method, a hydro-entangling method, a water vapor flow(steam jetting) entangling method, and the like. Since the formation ofthe plurality of first areas is carried out by a hydroentangling method,it may be preferable to carry out the entanglement of fibers in thesecond area by a hydroentangling method. In other embodiments, thesecond area comprises thermal-fused fibers.

The nonwoven of the present invention provides a cushiony and softsensory as well as a pattern as the second area maintains an originalcaliper during the hydroentanglement process.

The plurality of first areas may comprise a pattern. Each of the firstareas may have a shape of a linear line, a curved line, a circle, anellipse, a triangle, a polygon, a chevron pattern, a lattice pattern, asawtooth pattern, a zigzag pattern, and the like. In some embodiments,the plurality of first areas comprise a repeated pattern at least in anonwoven lengthwise direction. Each of the plurality of first areas arenot necessarily in the same shape or size.

In some embodiments, the plurality of first areas are continuous in anonwoven widthwise direction which corresponds to a cross-machinedirection. In other embodiments, the plurality of first areas arediscrete in a nonwoven widthwise direction so that the plurality offirst areas is surrounded by the second area. Referring to FIG. 6 , inan embodiment, a hydroentangled nonwoven 600 of the present inventionhas a plurality of first areas 610 discrete in a nonwoven widthwisedirection and a second area 620 surrounding the plurality of first areas610.

The nonwoven web of the present invention may further comprise aplurality of third areas comprising hydroentangled fibers. The pluralityof third areas may be formed simultaneously when the plurality of firstareas are formed. The plurality of third areas may be formed prior to orafter forming the plurality of first areas. The plurality of third areasmay also be formed in such a manner as to intersect a portion of theplurality of first areas, may also be formed between adjacent aplurality of first areas, and may also be formed inside the plurality offirst areas. The plurality of third areas may have the same shape as thefirst areas. The third areas may have a different shape from the firstareas. The third areas may be continuous in a nonwoven lengthwisedirection. The third areas may be discrete in a nonwoven lengthwisedirection. Referring to FIG. 7 , in an embodiment, a hydroentanglednonwoven 700 of the present invention has a plurality of third areas 730as well as a plurality of first areas 710 discrete in a nonwovenwidthwise direction and at least one second area 720 between twoadjacent first areas 710 in a nonwoven lengthwise direction.

Included in the hydroentangled nonwoven can be fibers of natural orman-made origin and may be staple fibers or continuous filaments or beformed in situ. The fibers can be a cellulosic fibrous component, anon-cellulosic fibrous component, a polyolefin-based binder fibrouscomponent, and any combination thereof. The polyolefin-based binderfibrous component can be a bicomponent fiber. As used hereinafter theterm bicomponent fibers refers to fibers having two constituents.

The nonwoven of the present invention can be manufactured from anassortment of suitable fiber types that produce the desired softness,mechanical performance and fluid handling performance considering finaluse of the nonwoven.

The nonwoven web of the present invention may have a basis weight ofabout 200 grams per square meter (gsm) or less, of bout 25-100 gsm, orof 30-60 gsm.

Laminate

The present invention also provides a laminate comprising a first layercomprising a nonwoven according to the present invention. The laminateof the present invention may further comprise a second layer comprisinga nonwoven web or film.

The nonwoven or the laminate according to the present invention can beincorporated into, for example, an absorbent article. For example, itcan be used as a component such as a topsheet for a sanitary napkin or adiaper.

Absorbent Article

The present invention also provides an absorbent article comprising alayer comprising a nonwoven or a laminate according to the presentinvention.

The absorbent article of the present invention may comprise a topsheetand a backsheet joined to the topsheet. The absorbent article of thepresent invention may further comprise an absorbent core disposedbetween the topsheet and the backsheet. In some embodiments, theabsorbent article of the present invention comprises a topsheet or alayer disposed below the topsheet comprising a nonwoven or a laminateaccording to the present invention.

The absorbent articles of the present invention may be producedindustrially by any suitable means. The different layers may thus beassembled using standard means such as embossing, thermal bonding,gluing or any combination thereof.

Topsheet

Topsheet can catch body fluids and/or allow the fluid penetration insidethe absorbent article. With the nonwoven according to the presentinvention, the first web layer is preferably, disposed on a side incontact with the skin.

Backsheet

Any conventional liquid impervious backsheet materials commonly used forabsorbent articles may be used as backsheet. In some embodiments, thebacksheet may be impervious to malodorous gases generated by absorbedbodily discharges, so that the malodors do not escape. The backsheet mayor may not be breathable.

Absorbent Core

It may be desirable that the absorbent article further comprises anabsorbent core disposed between the topsheet and the backsheet. As usedherein, the term “absorbent core” refers to a material or combination ofmaterials suitable for absorbing, distributing, and storing fluids suchas urine, blood, menses, and other body exudates. Any conventionalmaterials for absorbent core suitable for absorbent articles may be usedas absorbent core.

EXAMPLES Example 1: Preparation of Nonwoven

Rayon fibers (1.7 Dtex, 57 mm length, Lenzing, China) and PE/PETsheath/core bicomponent fibers (2.2 Dtex, 57 mm length, JNC, Japan) aremixed with a ratio of 80 wt % to 20 wt % and form a fibrous web with abasis weight of 40 gsm through a carding process. The fibrous web movesat a speed of 50 meter/min to a first hydroentanglement system havingtwo injectors. Water jets from a first injector are applies at 3.0 MPato the fibrous web, and then water jets from a second injector areapplied at 2.5 MPa to the opposite side of the fibrous web to furtherentangle fibers in the fibrous web.

Then the fibrous web is moved to a second hydroentanglement systemsimilar to one shown in FIGS. 3A-3C. Referring to FIG. 3A, water jets 36from an injector 32 of the second hydroentanglement system are appliedat 5.0 MPa to the fibrous web 30. The second hydroentanglement systemhas an apertured hollow cylinder 50 having apertures 52 with 2 mm ofdiameter in a 2 mm distance between two adjacent apertures 52. Theapertured cylinder 50 has a diameter of 3 inches, is disposed betweenthe injector 32 and the fibrous web 30, and rotates along an axis Xperpendicular to a z-direction. During rotation, the apertured cylinder50 moves back and forth in a cross-machine direction with a 15 mm rangeand a frequency of 20 rounds/sec between a blocking position where atleast one water jet 36 a from the injector 32 is blocked by theapertured cylinder 50, and an open position where at least the water jet36 a from the injector 32 passes through an aperture 52 of the aperturedcylinder 50.

A hydroentangled nonwoven 600 shown in FIG. 6 having a plurality offirst areas 610 discrete in a machine direction, and a second area 620is produced. The obtained nonwoven web goes through a dryer to dry thenonwoven. The obtained nonwoven goes through a dryer to dry thenonwoven.

Example 2: Preparation of Nonwoven

A hydroentangled nonwoven is produced according to the process disclosedin Example 1. Bleached cotton fibers (1.7 Dtex, 57 mm length, MarusanCo., LTD, CN) and PE/PET sheath/core bicomponent fibers (2.2 Dtex, 57 mmlength, JNC, Japan) are mixed with a ratio of 80 wt % to 20 wt % andfrom a fibrous web. The fibrous web moves at a speed of 50 meter/min toa first hydroentanglement system having two injectors and ishydroentangled under the conditions disclosed in Example 1. Then thefibrous web is moved to a second hydroentanglement system as disclosedin Example 1. The second hydroentanglement system has an aperturedhollow cylinder having a diameter of 3 inches, and rotating along theaxis X in a speed of 1.73 rounds/sec (50 meter/min). The aperturedcylinder has apertures. A distance between two adjacent apertures isabout 60 mm in a cross-machine direction, and about 80 mm in a machinedirection. The obtained nonwoven goes through a dryer to dry thenonwoven.

The obtained hydroentangled nonwoven 800 shown in FIG. 8 has a pluralityof first areas 710 discrete in a machine direction and a second area820. The nonwoven 700 can be used as a topsheet 1 of a sanitary napkin10 as shown in FIG. 9 in such a way that the first area 810, anapertured pattern, is positioned in a center area of the sanitary napkin10.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for making a nonwoven comprising aplurality of first areas comprising hydroentangled fibers, the processcomprising: subjecting a fibrous web to a first hydroentanglementprocess directing water jets from a water injection means comprising aplurality of orifices on to the fibrous web, blocking at least one waterjet from the water injection means discontinuously using a firstblocking member positioned between the water injection means and thefibrous web, wherein the first blocking member comprises at least oneaperture or recess, and is rotatable about an axis perpendicular to az-direction, wherein the axis of the blocking member is between thewater injection means and the fibrous web and wherein the plurality offirst areas are discrete in a machine direction.
 2. The processaccording to claim 1, wherein the first blocking member moves back andforth along a first axis between a first position where the firstblocking member blocks the at least one water jet from the waterinjection means and a second position where the first blocking memberdoes not block the at least one water jet from the water injectionmeans.
 3. The process according to claim 1, wherein the first blockingmember comprises a plurality of apertures.
 4. The process according toclaim 1, wherein the first blocking member comprises at least one recesson its surface.
 5. The process according to claim 2, wherein the firstaxis is parallel to a machine direction or to a cross machine direction.6. The process according to claim 1, wherein the fibrous web subjectedto the first hydroentanglement process is an entangled web or a thermalbonded web.
 7. The process according to claim 1, wherein the processfurther comprises subjecting the fibrous web to an entanglement processprior to the first hydroentanglement process.
 8. The process accordingto claim 1, wherein the process further comprises subjecting the fibrousweb to an entanglement process after the first hydroentanglementprocess.
 9. The process according to claim 7, wherein the entanglementprocess is a hydroentanglement process.